Bulletin: ABIB-0801R1
Date: October 22, 2010
Bulletin Type: Service
Topic: NEW REDESIGNED 40K TANDEM CARRIERS
____________________________________________________________
Affected Models:
All D344, 404, 405, DST40, 41, DSP40, 41, DSH40, DSH44 (includes Diff Lock and Pump option models)
Issue Description:
Dana has engineered in a significant product upgrade to the current 40K tandem axles. At the core of
these product enhancements is the incorporation of Dana’s patented and proven OnDemand™ lube
pump. This innovative lubrication system operates primarily during spinout situations. The remaining
99+% of the time, the pump is idle and ready to be activated instantaneously, in forward or reverse.
When compared to competitive axles that continuously operate a lube pump, this efficiency upgrade
saves up to 2HP and also decreases oil sump temperature by as much as 20°F. The wasted HP incurred
by the other axles relates directly to reduced fuel economy, higher temperatures in the lube sump, and
reduced lubricant life. The new design carriers have been optimally designed such that there is now a
12lbs weight savings on pump carriers and 5lbs for the non-pump models. This same system is currently
used in the D170 and D190 family of heavy duty tandems.
SERVICE PARTS IMPACT: Production of the new design units in North America begins June 16, 2008.
These design upgrades will impact customers who stock parts or service carriers for the models listed
above. Service Carriers are completely interchangeable as units.
are not interchangeable! It is important for customers to beware of the part number changes and in
time begin making stocking adjustments accordingly.
The material contained in this bulletin is product improvement information. Dana Corporation is not
Dana OnDemand™ lube
pump now available in 40K
tandem carriers
committed to, or liable for, canvassing existing products.
New Input Shaft
for Lube pump
Lube pump located inside
new output shaft side gear
Individual internal parts and kits
Page 1 of 6
INFORMATION BULLETIN - ABIB-0801R1 – NEW REDESIGNED 40K TANDEM CARRIERS
Original
d
esign
s
ervice
c
arriers are c
ompletely
New Service Part Numbers:
Outlined below are the newly released service parts. Dealers should begin to maintain an initial level of these
parts going forward as the individual parts between the old and new are not compatible. All parts for the older
design carriers will continue to be offered thru service.
• BASIC OVERHAUL KITS – Dana has reduced the complexity of the repaired kits offered on the
w carriers by only releasing Basic Overhaul Kits. Two new kits have been released that come
ne
complete with all the necessary bearings, shims, washers and RTV sealant required when doing an
overhaul.
NEW OVERHAUL KIT PART NUMBERS:
504030 – Basic Overhaul Kit – D40K Standard Models – AFTER 6.16.08
504031 – Basic Overhaul Kit – D40K Diff-Lock Models – AFTER 6.16.08
• INPUT SHAFT KITS – The new design carriers now utilize a “Pump” version and a “Non Pump”
version input shaft. The part number of the shaft is stamped on the part for easy identification. Each
shaft is sold thru service in a kit form that includes the nut, thrust washer and torque information
sheet.
NEW INPUT SHAFT KIT PART NUMBERS:
504026 – Input Shaft Kit - Non Pump (shaft p/n 132447)
504027 – Input Shaft Kit - Pump Models (shaft p/n 132446)
• LUBE PUMP, OUTPUT SHAFT SIDE GEARS AND LOOSE PARTS – Listed below are
the balance of the new individual service parts located in the power divider section of the forward
carrier. These parts are related directly to the new design lube pump system. Detailed parts and
illustrations are shown on page 3 of this bulletin.
IM
pump design. Do not to mix these parts. Use pump model output shafts with pump model input shafts as well as non pump
output shaft side gear with non pump input shafts! Mixed parts will assemble together, but they are not designed to run
together and failure will occur if any parts are mixed.
NEW KITS AND LOOSE PART NUMBERS:
504028 – Lube Pump Parts Kit – Pump Models
504029 – Manifold Parts Kit – Pump Models
132061 – Output Side Gear – Pump Models (only sold as kit# 504028)
133964 – Filter Screen Assembly – Pump Models
134010 – Collar Lock – Pump Models
134011 – Lube Hose – Pump Models
132060 – Bearing Cone – Pump and Non Pump Models
132443 – Output Side Gear – Non Pump Models
• SERVICE CARRIERS – The service carriers are completely interchangeable as a unit but the
components inside are not. Knowing the design level being serviced is very important when ordering
replacement parts for any repairs or overhauls. New Service Carrier part numbers have been
released so customers can take advantage of the new design. The old design service carriers will be
phased out. Refer to pages 4-6 of this bulletin for a complete crossover listing of carrier part
numbers.
[Models: DS344, DS404, DS405, DSP40, DSP41, DST40, DST41, DSH40, DSH44]
[Models: DD404, DDP40, DDP41, DDH40, DDH44]
PORTANT NOTE: The output shaft side gears are designed for use with specific input shafts, i.e. pump design vs. non
interchangeable with new design service carriers!
Page 2 of 6
INFORMATION BULLETIN - ABIB-0801R1 – NEW REDESIGNED 40K TANDEM CARRIERS
NEW DESIGN FORWARD CARRIER POWER DIVIDER:
SERVICE KITS and LOOSE PARTS LISTING:
504026 – Input Shaft Kit - Non Pump (includes items 11a, plus 128049 nut, 132439 washer - not shown below)
504027 – Input Shaft Kit - Pump Models (includes items 11b, plus 128049 nut, 132439 washer - not shown below)
504028 – Lube Pump Kit – D40P (includes items 7-8, 9b-10)
504029 – Manifold Parts Kit – D40K Pump Models (includes items 2-4, 5b)
880 – Manifold Parts Kit – D40K Non-Pump Models (includes item 5a)
513
504030 – Basic Overhaul Kit – D40K Standard Models
504031 – Basic Overhaul Kit – D40K Diff-Lock Models
1a. 132038 – Forward Carrier/Cap – Standard Models - NSS (Spicer Service Kit is: 132466)
1b. 132043 – Forward Carrier/Cap – Diff-Lock Models - NSS (Spicer Service Kit is: 132467)
2. 133964 – Filter Screen Assembly
3a. 134010 – Collar Lock (located on filter end of hose)
3b. 129338 – Clamp (located on manifold end of hose)
4. 134011 – Lube Hose
5a. 132435 – Seal Manifold Assembly – Non Pump Models (sold only in kit# 513880)
5b. 131366 – Seal Manifold Assembly – Pump Models (sold only in kit# 504029)
6. 110811 – Bearing Race
7. 132060 – Bearing Cone
8. 131541 – Pin
9a. 132443 – Output Side Gear – Non Pump Models (note: ID=1.81”)
9b. 132061 – Output Side Gear – Pump Models (only sold in kit# 504028) (note: ID=2.08”)
10 131368 – Lube Pump (sold as part of kit# 504028)
11a. 132447 – Input Shaft – Non Pump Models (sold only as kit# 504026)
11b. 132446 – Input Shaft – Pump Models (sold only as kit# 504027)
Note 1: The new base Carrier/Cap (item#1) is designed to use NEW style parts only. It is not possible to retrofit or interchange OLD and
NE
W design parts.
Page 3 of 6
INFORMATION BULLETIN - ABIB-0801R1 – NEW REDESIGNED 40K TANDEM CARRIERS
674862
682862
675634
682634
674863
682863
674864
682864
674865
682865
674866
682866
674867
682867
674868
682868
674869
682869
674870
682870
674871
682871
674872
682872
674873
682873
674874
682874
674875
682875
674876
682876
675200
682200
675201
682201
676114
682114
675202
682202
675203
682203
675204
682204
675205
682205
675206
682206
675207
682207
675208
682208
675209
682209
675210
682210
675211
682211
675212
682212
675213
682213
675214
682214
675510
682510
675251
682251
675252
682252
675253
682253
675254
682254
675255
682255
675256
682256
675257
682257
675258
682258
675259
682259
675260
682260
675261
682261
675262
682262
675263
682263
675264
682264
675265
SERVICE CARRIER DD404, 6.50
682265
675303
682303
675304
682304
675305
682305
675306
682306
675307
682307
675308
682308
675309
682309
675310
682310
675311
682311
675312
682312
675313
682313
675314
682314
675315
682315
675316
682316
675317
682317
675318
682318
ORIGINAL design carriers and NEW design carriers are completely interchangeable as a unit! Shown below
are replacement reference charts sorted by model family. Print and use as a quick reference guide!
Old Carrier
Part-No
675883
675884
675885
675886
675887
675888
675889
675890
675891
675892
675893
675894
675895
675896
675897
675898
675899
Description
SERVICE CARRIER DS344, 2.64
SERVICE CARRIER DS344, 2.85
SERVICE CARRIER DS344, 2.93
SERVICE CARRIER DS344, 3.08
SERVICE CARRIER DS344, 3.25
SERVICE CARRIER DS344, 3.36
SERVICE CARRIER DS344, 3.55
SERVICE CARRIER DS344, 3.70
SERVICE CARRIER DS344, 3.90
SERVICE CARRIER DS344, 4.11
SERVICE CARRIER DS344, 4.33
SERVICE CARRIER DS344, 4.63
SERVICE CARRIER DS344, 4.88
SERVICE CARRIER DS344, 5.29
SERVICE CARRIER DS344, 5.57
SERVICE CARRIER DS344, 6.17
SERVICE CARRIER DS344, 6.50
New Carrier
Part-No.
682883
682884
682885
682886
682887
682888
682889
682890
682891
682892
682893
682894
682895
682896
682897
682898
682899
D344, D404(P), D405(P) FAMILY
• Primary Gearing – Standard*
• Wheel Differential Parts - Standard
• Carrier Bearings – Standard
*standard gearing used in majority of production builds
Old Carrier
Part-No
674861
Description
SERVICE CARRIER DS404, 2.64
SERVICE CARRIER DS404, 2.85
SERVICE CARRIER DS404, 2.93
SERVICE CARRIER DS404, 3.08
SERVICE CARRIER DS404, 3.25
SERVICE CARRIER DS404, 3.36
SERVICE CARRIER DS404, 3.55
SERVICE CARRIER DS404, 3.70
SERVICE CARRIER DS404, 3.90
SERVICE CARRIER DS404, 4.11
SERVICE CARRIER DS404, 4.33
SERVICE CARRIER DS404, 4.63
SERVICE CARRIER DS404, 4.88
SERVICE CARRIER DS404, 5.29
SERVICE CARRIER DS404, 5.57
SERVICE CARRIER DS404, 6.17
SERVICE CARRIER DS404, 6.50
New Carrier
Part-No.
682861
Old Carrier
Part-No
Description
SERVICE CARRIER DS404P, 2.64
SERVICE CARRIER DS404P, 2.85
SERVICE CARRIER DS404P, 2.93
SERVICE CARRIER DS404P, 3.08
SERVICE CARRIER DS404P, 3.25
SERVICE CARRIER DS404P, 3.36
SERVICE CARRIER DS404P, 3.55
SERVICE CARRIER DS404P, 3.70
SERVICE CARRIER DS404P, 3.90
SERVICE CARRIER DS404P, 4.11
SERVICE CARRIER DS404P, 4.33
SERVICE CARRIER DS404P, 4.63
SERVICE CARRIER DS404P, 4.88
SERVICE CARRIER DS404P, 5.29
SERVICE CARRIER DS404P, 5.57
SERVICE CARRIER DS404P, 6.17
New Carrier
Part-No.
Old Carrier
Part-No
Description
SERVICE CARRIER DD404, 2.64
SERVICE CARRIER DD404, 2.85
SERVICE CARRIER DD404, 3.08
SERVICE CARRIER DD404, 3.25
SERVICE CARRIER DD404, 3.36
SERVICE CARRIER DD404, 3.55
SERVICE CARRIER DD404, 3.70
SERVICE CARRIER DD404, 3.90
SERVICE CARRIER DD404, 4.11
SERVICE CARRIER DD404, 4.33
SERVICE CARRIER DD404, 4.63
SERVICE CARRIER DD404, 4.88
SERVICE CARRIER DD404, 5.29
SERVICE CARRIER DD404, 5.57
SERVICE CARRIER DD404, 6.17
New Carrier
Part-No.
Old Carrier
Part-No
Description
SERVICE CARRIER DD404P, 2.64
SERVICE CARRIER DD404P, 2.85
SERVICE CARRIER DD404P, 3.08
SERVICE CARRIER DD404P, 3.25
SERVICE CARRIER DD404P, 3.36
SERVICE CARRIER DD404P, 3.55
SERVICE CARRIER DD404P, 3.70
SERVICE CARRIER DD404P, 3.90
SERVICE CARRIER DD404P, 4.11
SERVICE CARRIER DD404P, 4.33
SERVICE CARRIER DD404P, 4.63
SERVICE CARRIER DD404P, 4.88
SERVICE CARRIER DD404P, 5.29
SERVICE CARRIER DD404P, 5.57
SERVICE CARRIER DD404P, 6.17
SERVICE CARRIER DD404P, 6.50
New Carrier
Part-No.
Page 4 of 6
INFORMATION BULLETIN - ABIB-0801R1 – NEW REDESIGNED 40K TANDEM CARRIERS
675981
682981
675982
682982
675983
682983
675984
682984
675985
682985
675986
682986
675987
682987
675988
682988
675989
682989
675990
682990
675991
682991
675992
682992
675993
682993
675994
682994
675995
682995
675996
682996
675997
682997
675998
682998
675999
682999
676000
682000
676001
682001
676002
682002
676003
682003
676004
682004
676005
682005
676006
682006
676007
682007
676008
682008
676009
682009
676010
682010
676011
682011
676012
682012
675967
682967
675968
682968
675969
682969
675970
682970
675971
682971
675972
682972
675973
682973
675974
682974
675975
682975
675976
682976
675977
682977
675978
682978
675979
682979
675980
682980
675949
682949
675950
682950
675951
682951
675952
682952
675953
682953
675954
682954
675955
682955
675956
682956
675957
682957
675958
682958
675959
682959
675960
682960
675961
682961
675962
682962
675963
682963
675964
682964
Old Carrier
Part-No
675965 SERVICE CARRIER DSP40, 2.64 682965
675966 SERVICE CARRIER DSP40, 2.93 682966
Old Carrier
Part-No
Old Carrier
Part-No
Description
SERVICE CARRIER DSP40, 3.08
SERVICE CARRIER DSP40, 3.25
SERVICE CARRIER DSP40, 3.36
SERVICE CARRIER DSP40, 3.55
SERVICE CARRIER DSP40, 3.70
SERVICE CARRIER DSP40, 3.90
SERVICE CARRIER DSP40, 4.11
SERVICE CARRIER DSP40, 4.33
SERVICE CARRIER DSP40, 4.63
SERVICE CARRIER DSP40, 4.88
SERVICE CARRIER DSP40, 5.29
SERVICE CARRIER DSP40, 5.57
SERVICE CARRIER DSP40, 6.17
SERVICE CARRIER DSP40, 6.50
Description
SERVICE CARRIER DSP40P, 2.64
SERVICE CARRIER DSP40P, 2.93
SERVICE CARRIER DSP40P, 3.08
SERVICE CARRIER DSP40P, 3.25
SERVICE CARRIER DSP40P, 3.36
SERVICE CARRIER DSP40P, 3.55
SERVICE CARRIER DSP40P, 3.70
SERVICE CARRIER DSP40P, 3.90
SERVICE CARRIER DSP40P, 4.11
SERVICE CARRIER DSP40P, 4.33
SERVICE CARRIER DSP40P, 4.63
SERVICE CARRIER DSP40P, 4.88
SERVICE CARRIER DSP40P, 5.29
SERVICE CARRIER DSP40P, 5.57
SERVICE CARRIER DSP40P, 6.17
SERVICE CARRIER DSP40P, 6.50
Description
SERVICE CARRIER DDP40, 2.64
SERVICE CARRIER DDP40, 2.93
SERVICE CARRIER DDP40, 3.08
SERVICE CARRIER DDP40, 3.25
SERVICE CARRIER DDP40, 3.36
SERVICE CARRIER DDP40, 3.55
SERVICE CARRIER DDP40, 3.70
SERVICE CARRIER DDP40, 3.90
SERVICE CARRIER DDP40, 4.11
SERVICE CARRIER DDP40, 4.33
SERVICE CARRIER DDP40, 4.63
SERVICE CARRIER DDP40, 4.88
SERVICE CARRIER DDP40, 5.29
SERVICE CARRIER DDP40, 5.57
SERVICE CARRIER DDP40, 6.17
SERVICE CARRIER DDP40, 6.50
New Carrier
Part-No.
New Carrier
Part-No.
New Carrier
Part-No.
DSP40(P), DSP41(P) FAMILY:
• High Capacity Premium Carrier Bearings
• Primary Gearing – Premium Processing
• Premium Wheel Differential Parts
• Thrust Bolt Standard
Old Carrier
rt-No
Pa
Description
SERVICE CARRIER DDP40P, 2.64
SERVICE CARRIER DDP40P, 2.93
SERVICE CARRIER DDP40P, 3.08
SERVICE CARRIER DDP40P, 3.25
SERVICE CARRIER DDP40P, 3.36
SERVICE CARRIER DDP40P, 3.55
SERVICE CARRIER DDP40P, 3.70
SERVICE CARRIER DDP40P, 3.90
SERVICE CARRIER DDP40P, 4.11
SERVICE CARRIER DDP40P, 4.33
SERVICE CARRIER DDP40P, 4.63
SERVICE CARRIER DDP40P, 4.88
SERVICE CARRIER DDP40P, 5.29
SERVICE CARRIER DDP40P, 5.57
SERVICE CARRIER DDP40P, 6.17
SERVICE CARRIER DDP40P, 6.50
New Carrier
Part-No.
Page 5 of 6
INFORMATION BULLETIN - ABIB-0801R1 – NEW REDESIGNED 40K TANDEM CARRIERS
675770
682770
675771
682771
675772
682772
675773
682773
675774
682774
675775
682775
675776
682776
675777
682777
675778
682778
675779
682779
675847
682847
675848
682848
676141
682141
676153
682153
681279
682279
675750
682750
675751
682751
675752
682752
675753
682753
675754
682754
675755
682755
675756
682756
675757
682757
675758
682758
675759
682759
675835
682835
675836
682836
676155
682155
676156
682156
675740
682740
675741
682741
675742
682742
675743
682743
675744
682744
675745
682745
675746
682746
675747
682747
675748
682748
675749
682749
675760
682760
675761
682761
675762
682762
675763
682763
675764
682764
675765
682765
675766
682766
675767
682767
675768
682768
675769
682769
Old Carrier
Part-No
Description
SERVICE CARRIER DSH40, 3.08
SERVICE CARRIER DSH40, 3.25
SERVICE CARRIER DSH40, 3.36
SERVICE CARRIER DSH40, 3.55
SERVICE CARRIER DSH40, 3.70
SERVICE CARRIER DSH40, 3.90
SERVICE CARRIER DSH40, 4.11
SERVICE CARRIER DSH40, 4.33
SERVICE CARRIER DSH40, 4.63
SERVICE CARRIER DSH40, 4.88
New Carrier
Part-No.
Old Carrier
Part-No
Old Carrier
Part-No
Description
SERVICE CARRIER DSH40P, 3.08
SERVICE CARRIER DSH40P, 3.25
SERVICE CARRIER DSH40P, 3.36
SERVICE CARRIER DSH40P, 3.55
SERVICE CARRIER DSH40P, 3.70
SERVICE CARRIER DSH40P, 3.90
SERVICE CARRIER DSH40P, 4.11
SERVICE CARRIER DSH40P, 4.33
SERVICE CARRIER DSH40P, 4.63
SERVICE CARRIER DSH40P, 4.88
Description
SERVICE CARRIER DDH40, 3.08
SERVICE CARRIER DDH40, 3.25
SERVICE CARRIER DDH40, 3.36
SERVICE CARRIER DDH40, 3.55
SERVICE CARRIER DDH40, 3.70
SERVICE CARRIER DDH40, 3.90
SERVICE CARRIER DDH40, 4.11
SERVICE CARRIER DDH40, 4.33
SERVICE CARRIER DDH40, 4.63
SERVICE CARRIER DDH40, 4.88
New Carrier
Part-No.
New Carrier
Part-No.
DSH40(P), DSH44(P) FAMILY:
• High Capacity Premium Carrier Bearings
• Larger Primary Gearing 15.75”
• Primary Gearing – Premium Processing
• Premium Wheel Differential Parts
• Premium Input & Output Shafts
• Thrust Bolt Standard
Old Carrier
rt-No
Pa
Description
SERVICE CARRIER DDH40P, 3.08
SERVICE CARRIER DDH40P, 3.25
SERVICE CARRIER DDH40P, 3.36
SERVICE CARRIER DDH40P, 3.55
SERVICE CARRIER DDH40P, 3.70
SERVICE CARRIER DDH40P, 3.90
SERVICE CARRIER DDH40P, 4.11
SERVICE CARRIER DDH40P, 4.33
SERVICE CARRIER DDH40P, 4.63
SERVICE CARRIER DDH40P, 4.88
New Carrier
Part-No.
Old Carrier
Part-No
Description
SERVICE CARRIER DSH44, 5.29
SERVICE CARRIER DSH44, 5.57
SERVICE CARRIER DSH44, 6.17
SERVICE CARRIER DSH44, 6.50
New Carrier
Part-No.
Page 6 of 6
Old Carrier
Part-No
Description
SERVICE CARRIER DSH44P, 5.29
SERVICE CARRIER DSH44P, 5.57
SERVICE CARRIER DSH44P, 6.17
SERVICE CARRIER DSH44P, 6.50
SERVICE CARRIER DSH44P, 7.17
New Carrier
Part-No.
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